Serviceable power inlet connector

Abstract

A power inlet connector assembly configured for use in charging an electric vehicle includes a housing subassembly (102) containing a plurality of direct current (DC) electrical terminals (104) configured for mating with corresponding DC electrical terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle, and a cover subassembly (202) configured for connecting and disconnecting with the housing subassembly (102). The cover subassembly (202) contains an electrical busbar (206) and an alternating current (AC) electrical terminal (208) having a first end (210) configured for mating with a corresponding AC electrical terminal of the power outlet connector of the electric vehicle charging device. The electrical busbar (206) is configured for connecting and disconnecting with the DC electrical terminals (104), and the AC electrical terminal (208) is configured for insertion into and removal from a terminal cavity defined by the housing subassembly (102).

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application No. Pending, filed on a pending date, which claims priority to U.S. Provisional Patent Application No. 63 / 243,036, filed on September 10, 2021, the entire disclosure of each of the above applications being incorporated herein by reference. Technical Field

[0003] The present invention generally relates to electrical connectors for charging electric vehicles, and more specifically to serviceable liquid-cooled power inlet connectors. Background Technology

[0004] Combination charging systems (CCS) are a standard for electrical connectors used to charge electric vehicles. They use both AC and DC connectors to provide electric power at levels up to 350 kW. A CCS has a power outlet connector attached to a charging station and a power inlet connector integrated into the electric vehicle. Existing CCS power inlet connectors are typically bulky and difficult to build and assemble. They often involve handling a large number of leads, resulting in significant assembly complexity. CCS power inlet connectors are also generally non-repairable and do not include liquid cooling. Summary of the Invention

[0005] According to one or more aspects of this disclosure, a power inlet connector assembly includes: a housing subassembly including a plurality of direct current (DC) terminals configured to mate with corresponding DC terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle. The power inlet connector assembly further includes a cover assembly configured to connect and disconnect from the housing subassembly. The cover assembly includes a plurality of busbars and a plurality of alternating current (AC) terminals having a first end configured to mate with a corresponding AC terminal of a power outlet connector of the electric vehicle charging device. The plurality of busbars are configured to connect and disconnect from the plurality of DC terminals, and the plurality of AC terminals are configured to be inserted into and removed from a terminal cavity defined by the housing subassembly.

[0006] In one or more embodiments of the power inlet connector assembly according to the foregoing paragraph, the housing subassembly includes a plurality of signal terminals configured to mate with corresponding signal terminals of the power outlet connector of the electric vehicle charging device.

[0007] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cover assembly defines a plurality of cable cavities configured to receive a plurality of DC cables attached to a plurality of busbars in an electric vehicle.

[0008] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, a plurality of cable cavities are oriented parallel to the longitudinal axis of a plurality of busbars, and a cover assembly is configured to dress a plurality of DC cables in a straight outward direction.

[0009] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, a plurality of cable cavities are oriented perpendicular to the longitudinal axis of a plurality of busbars.

[0010] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cover assembly may be configured to wrap around a plurality of DC cables in a right-hand, left-hand, or downward direction.

[0011] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cover assembly defines an access port that is positioned, sized, and arranged to allow tools to access an interface between multiple DC cables and multiple busbars. The cover assembly further includes a removable access plug configured to enclose the access port.

[0012] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cover assembly further includes a cooling plate thermally coupled to, but electrically isolated from, a plurality of busbars.

[0013] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cooling plate is liquid-cooled.

[0014] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cooling plate is air-cooled.

[0015] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the cover assembly further includes a shield configured to receive a connector having multiple electrical terminals terminating multiple AC cables in an electric vehicle. The multiple electrical terminals are configured to mate with a second end of the multiple AC electrical terminals.

[0016] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the power inlet connector assembly further includes an AC cable connector having a plurality of AC cable terminals terminating a plurality of AC cables in an electric vehicle. The plurality of AC cable terminals are configured to mate with a second end of the plurality of AC terminals. The cover assembly further includes a shield configured to receive the AC cable connector.

[0017] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the AC cable connector includes a connector subassembly, the connector subassembly including a housing, a connector position guarantee (CPA) device, a connector seal configured to seal the housing to a shield, and a connector seal retainer.

[0018] In one or more embodiments of the power inlet connector assembly according to any of the preceding paragraphs, the AC cable connector includes a terminal position assurance (TPA) device in which a plurality of AC electrical terminals are received, a cable seal, and a cable seal retainer disposed within the connector subassembly.

[0019] According to one or more aspects of this disclosure, a method for assembling and disassembling a power inlet connector configured for use in charging an electric vehicle includes the following steps:

[0020] • Provide a housing subassembly, which includes multiple DC terminals configured to mate with corresponding DC terminals of the power output connector of an electric vehicle charging device external to the electric vehicle;

[0021] • Provides a cover assembly comprising multiple electrical busbars and multiple AC electrical terminals, the multiple AC electrical terminals having a first end configured to mate with a corresponding AC electrical terminal of a power output connector for an electric vehicle charging device;

[0022] Insert multiple AC terminals into the terminal cavity defined by the housing subassembly.

[0023] • Connect the housing subassembly to the cover assembly; and

[0024] Connect multiple busbars to multiple DC terminals.

[0025] In one or more embodiments of the method according to the foregoing paragraph, the method further includes the following steps:

[0026] • An AC cable connector with multiple AC cable terminals is inserted into a cover assembly that terminates multiple AC cables in an electric vehicle; and

[0027] • Connect multiple AC cable terminals to the second end of multiple AC terminals.

[0028] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the step of accessing an interface between a plurality of DC cables and a plurality of electrical busbars in an electric vehicle via an access port in the cover assembly, the access port being positioned, sized, and arranged to allow vehicle access.

[0029] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the following steps:

[0030] • Disconnect multiple busbars from multiple DC terminals;

[0031] • Disconnect the housing subassembly from the cover assembly; and

[0032] • Remove multiple AC terminals from the terminal cavities within the housing subassembly.

[0033] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the following steps:

[0034] • Disconnect multiple AC cable terminals from the second end of multiple AC terminals; and

[0035] Remove the AC cable connector from the cover.

[0036] According to one or more aspects of this disclosure, a power inlet connector assembly includes: a unitized housing subassembly comprising a plurality of electrical terminals configured to mate with corresponding electrical terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle; and a unitized cover assembly configured to connect and disconnect from the housing subassembly, and further configured to connect the plurality of electrical terminals to DC and AC cables in the electric vehicle. The housing subassembly and cover assembly are configured to be disconnected and replaced independently for servicing the power inlet connector assembly. Attached Figure Description

[0037] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0038] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0039] Figure 1A front perspective view of a power inlet connector assembly configured for use in charging an electric vehicle, according to some embodiments, is shown.

[0040] Figure 2 Illustrations are shown according to some embodiments Figure 1 Rear perspective view of the power input connector assembly;

[0041] Figure 3 Illustrations are shown according to some embodiments Figure 1 An exploded view of the power input connector assembly;

[0042] Figure 4A A perspective view of an AC cable connector according to some embodiments is shown, the AC cable connector having multiple electrical terminals terminating multiple AC cables in an electric vehicle, these electrical terminals being configured for use with... Figure 1 The power input connector assembly is connected.

[0043] Figure 4B Illustrations are shown according to some embodiments Figure 4A An exploded view of the external components of an AC cable connector;

[0044] Figure 4C Illustrations are shown according to some embodiments Figure 4A An exploded view of the internal components of an AC cable connector;

[0045] Figures 5A-5D A perspective view is shown of various DC cable routing and liquid coolant piping options for a power inlet connector assembly according to some embodiments;

[0046] Figure 6 A perspective view of an air-cooled embodiment of a power inlet connector assembly according to some embodiments is shown; and

[0047] Figure 7 A flowchart illustrating a method for assembling and disassembling a power inlet connector configured for use in charging an electric vehicle, according to some embodiments, is shown. Detailed Implementation

[0048] This paper presents a power inlet connector for charging electric vehicles that overcomes the shortcomings of existing designs. Given that power inlet connectors typically undergo numerous mating / unmating cycles, there is a need to make them replaceable and / or serviceable “devices” or components, especially when they are liquid-cooled. The power inlet connector presented herein is designed to be fully serviceable and provides a “device” that allows users to directly insert a power outlet connector into it, thus significantly simplifying the wiring harness assembly process for electric vehicles compared to existing designs. This makes the power inlet connector a “pluggable” solution. The power inlet connector presented here is a serviceable, liquid-cooled inlet connector with two sub-assemblies that can be individually replaced and / or serviced by automotive technicians in vehicle repair facilities such as car dealerships. This feature is achieved through a special design of the power inlet connector’s rear cover assembly.

[0049] Figures 1 to 3 The image shows a non-limiting example of a liquid-cooled power inlet connector assembly (hereinafter referred to as the assembly) configured for use in charging an electric vehicle. The power inlet connector assembly consists of two separate replaceable sub-assemblies, specifically, a housing sub-assembly 102 and a rear cover assembly 202, as described below.

[0050] The housing subassembly 102 has a housing 104 containing a pair of direct current (DC) terminals 106 configured to mate with corresponding DC terminals (not shown) of a corresponding power outlet connector, which is part of an electric vehicle charging device located outside and separate from the electric vehicle. The housing subassembly 102 also includes a trim member 108 covering a portion of the outer surface of the housing 104 and may include a spring-loaded dust cover 110 configured to protect the DC terminals 106 when not in use.

[0051] The rear cover assembly 202 is configured for connection and disconnection with the housing subassembly 102. The rear cover assembly 202 has a cover housing 204 containing a pair of electrical busbars 206 configured for connection and disconnection with a plurality of DC electrical terminals 106 in the housing subassembly 102. The rear cover assembly 202 also includes three alternating current (AC) electrical terminals 208 having a first end 210 configured for mating with corresponding AC electrical terminals (not shown) of a power outlet connector of an electric vehicle charging device. The AC electrical terminals 208 are configured for insertion and removal from a terminal cavity 112 defined by the housing subassembly 102. Figures 1-3 In the example of the power inlet connector assembly shown, the rear cover assembly 202 also includes a liquid-cooled cooling plate 212 thermally coupled to the busbar 206. The cooling plate 212 is electrically isolated from the busbar 206 to prevent short circuits between them.

[0052] The housing subassembly 102 also includes a peripheral seal 114 that seals the interface between the housing subassembly 102 and the rear cover assembly 202 to prevent environmental contaminants (such as water, oil, or dust) from entering the power inlet connector assembly. The housing subassembly 102 also includes controller circuitry 116 for the power inlet connector assembly. The housing subassembly 102 further includes a signal terminal 118 configured to connect the control circuitry 116 to a corresponding signal terminal (not shown) in the power outlet connector, thereby establishing signal communication between the power inlet connector assembly and the electric vehicle charging device to manage the DC or AC charging process. The housing subassembly 102 also includes a terminal seal 120 for sealing the signal terminal 118 of the housing subassembly 102 and the AC terminal 208 of the rear cover assembly 202, an actuator 122, and a retainer 124 for securing these components within the housing subassembly 102. The actuator 122 is configured to lock the power outlet connector of the electric vehicle charging device to the power inlet connector assembly during charging. This is designed to prevent disconnection during the charging process, which could result in arcing and / or exposure to hot terminals.

[0053] The rear cover assembly 202 also includes a pair of cable cavities 214 configured to receive a DC cable 216 from an electric vehicle. The DC cable 216 is welded to the busbar 206, for example, using an acoustic welding process. The busbar 206 is also secured with threaded fasteners (see [link to fastener description]). Figure 3 The tool is attached to DC terminal 106 via access port 218 in the rear cover assembly 202, which allows the tool to access the threaded fastener. The rear cover assembly 202 additionally includes a removable access plug 220 configured to enclose the access port 218.

[0054] like Figure 2 As shown, the rear cover assembly 202 further includes a shield 222 configured to receive the AC cable connector 302, also as Figure 4A As shown, the AC cable connector 302 has three AC cable terminals 304 that terminate the AC cable 306 from the electric vehicle. The AC cable terminals 304 are configured to mate with the second end 224 of the AC terminal 208 in the rear cover assembly 202. Figure 4BAs shown, the AC cable connector 302 includes a connector sub-assembly 308 comprising a housing 310, a connector position guarantee (CPA) device 312, a connector seal 314 configured to seal the housing 310 to a housing 222, and a connector seal retainer 316. Figure 4C As shown, the AC cable connector 302 additionally includes a terminal position assurance (TPA) device 318 in which AC electrical terminals 208 are received, a cable seal 320, and a cable seal retainer 322 disposed within the connector subassembly 308.

[0055] Figures 5A to 5C An embodiment of the power inlet connector assembly is shown, wherein the DC cable 216 and coolant connection 226 on the cooling plate 212 are oriented along an axis Y or axis Z perpendicular to the longitudinal axis X of the busbar 206 (see [link]). Figure 3 The rear cover assembly 202 can be configured for use in the right-hand direction ( Figure 5A ), to the left ( Figure 5B ) or downward direction ( Figure 5C The upper part is lined with multiple DC cables 216 and coolant piping. Figure 5D An embodiment of the power inlet connector assembly is shown, wherein the DC cable 216 and coolant connection 226 on the cooling plate 212 are oriented parallel to the longitudinal axis X of the busbar 206, and the rear cover assembly 202 is configured to wrap the DC cable 216 and coolant line in a straight outward direction.

[0056] Figure 6 An alternative embodiment of the power inlet connector assembly is shown, which is air-cooled rather than liquid-cooled. The cooling plate 212 includes cooling fins on the outer side of the rear cover assembly 202 to draw heat away from the busbar 206.

[0057] Figure 7 A flowchart illustrates a method 400 for assembling and disassembling a power inlet connector configured for use in charging an electric vehicle. The method includes the following steps:

[0058] Step 402, providing a housing subassembly 102 including a DC terminal 106 configured to mate with a corresponding DC terminal of a power output connector of an electric vehicle charging device external to the electric vehicle;

[0059] Step 404, providing a rear cover assembly 202 including a busbar 206 and an AC terminal 208, the AC terminal having a first end 210 configured to mate with a corresponding AC terminal of a power output connector of an electric vehicle charging device.

[0060] Step 406: Insert the AC terminal 208 into the terminal cavity 112 defined by the housing subassembly 102;

[0061] Step 408: Connect housing subassembly 102 to rear cover assembly 202;

[0062] Step 410: Connect the interface between the DC cable 216 and the busbar 206 in the electric vehicle through the access port 218 in the rear cover assembly 202. The access port 218 is positioned, sized, and arranged to allow the tool to access the interface.

[0063] Step 412: Connect busbar 206 to DC terminal 106;

[0064] Step 414, inserting an AC cable connector 302 having three AC cable terminals 304 into a cover 222 defined by a rear cover assembly 202, the three AC cable terminals terminating multiple AC cables 306 in the electric vehicle.

[0065] Step 416: Connect the multiple AC cable terminals 304 to the second end 224 of the AC terminal 208;

[0066] Step 418: Disconnect busbar 206 from DC terminal 106;

[0067] Step 420: Disconnect housing subassembly 102 from rear cover assembly 202;

[0068] Step 422: Remove the AC terminal 208 from the terminal cavity 112 in the housing subassembly 102;

[0069] Step 424, disconnect the plurality of AC cable terminals 304 from the second end 224 of the AC terminal 208; and

[0070] Step 426: Remove AC cable connector 302 from cover 222.

[0071] While the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted for elements therein without departing from the scope of the invention. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from its essential scope. Therefore, the invention is not limited to the disclosed one or more embodiments, but will include all embodiments falling within the scope of the appended claims.

[0072] As used herein, “one or more” includes functions performed by a single element, functions performed by more than one element, such as in a distributed manner, several functions performed by a single element, several functions performed by several elements, or any combination of the foregoing.

[0073] It will be understood that while the terms first, second, etc., are used in some instances to describe various elements herein, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various described embodiments. Both the first contact and the second contact are contacts, but they are not the same contact.

[0074] The terminology used in the description of the various embodiments described herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context otherwise clearly indicates otherwise. It will also be understood that the term “and / or,” as used herein, refers to and covers any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprising,” “including,” “containing,” and / or “comprising” as used in this specification indicate the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0075] As used herein, depending on the context, the term "if" may optionally be interpreted as "when," "after," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determined" or "if detected [the stated condition or event]" may optionally be interpreted as "after determining," "in response to determination," "after detecting [the stated condition or event]," or "in response to detecting [the stated condition or event]."

[0076] Additionally, although the terms of law or orientation may be used herein, these elements should not be limited by such terms. Unless otherwise stated, all terms of law or orientation are for the purpose of distinguishing one element from another and, unless otherwise stated, do not indicate any particular order, sequence of operations, direction, or orientation.

Claims

1. A power inlet connector assembly configured for use in charging an electric vehicle, the power inlet connector assembly comprising: The housing subassembly (102) includes a plurality of direct current (DC) terminals (106) configured to mate with corresponding DC terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle. as well as A rear cover assembly (202), configured to connect and disconnect from the housing subassembly (102), the cover assembly (202) including a plurality of busbars (206) and a plurality of AC terminals (208), the plurality of AC terminals (208) having a first end (210) configured to mate with a corresponding AC terminal of a power outlet connector of an electric vehicle charging device, wherein the plurality of AC terminals (208) are configured to be inserted into a terminal cavity defined by the housing subassembly (102) and Removed from the terminal cavity, wherein the rear cover assembly (202) further includes a threaded fastener configured to connect and disconnect with a pair of electrical busbars (206) and a pair of DC terminals (106), wherein the threaded fastener is accessible via an access port (218) in the rear cover assembly (202) that allows tools to access the threaded fastener, and wherein the cover assembly (202) additionally includes a removable access plug (220) configured to enclose the access port (218).

2. The power input connector assembly according to claim 1, characterized in that, The housing subassembly (102) includes a plurality of signal terminals (118) configured to engage with corresponding signal terminals of the power output connector of the electric vehicle charging device.

3. The power input connector assembly according to claim 1, characterized in that, The cover assembly (202) defines a plurality of cable cavities (214) configured to receive a plurality of DC cables (216) attached to the plurality of busbars (206) in the electric vehicle.

4. The power input connector assembly according to claim 3, characterized in that, The plurality of cable cavities (214) are oriented parallel to the longitudinal axis (X) of the plurality of busbars (206), and the cover assembly (202) is configured to wrap the plurality of DC cables (216) in a straight outward direction.

5. The power input connector assembly according to claim 3, characterized in that, The plurality of cable cavities (214) are oriented perpendicular to the longitudinal axis (X) of the plurality of busbars (206).

6. The power input connector assembly according to claim 5, characterized in that, The cover assembly (202) can be configured to wrap the plurality of DC cables (216) in a rightward, leftward, or downward direction.

7. The power input connector assembly according to claim 1, characterized in that, The cover assembly (202) further includes a cooling plate (212) that is thermally coupled to the plurality of busbars (206) but electrically isolated from the plurality of busbars (206).

8. The power input connector assembly according to claim 7, characterized in that, The cooling plate (212) is liquid cooled.

9. The power input connector assembly according to claim 7, characterized in that, The cooling plate (212) is air-cooled.

10. The power input connector assembly according to claim 1, characterized in that, The cover assembly (202) further includes a shield (222) configured to receive a connector (302) having a plurality of electrical terminals (304) terminating a plurality of AC cables (306) in the electric vehicle, wherein the plurality of electrical terminals (304) are configured to mate with a second end (224) of the plurality of AC electrical terminals (208).

11. The power input connector assembly of claim 1, further comprising: AC cable connector (302) having a plurality of AC cable terminals (304) terminating a plurality of AC cables (306) in the electric vehicle, wherein the plurality of AC cable terminals (304) are configured to mate with a second end (224) of the plurality of AC terminals (208), and wherein the cover assembly (220) further includes a shield (222) configured to receive the AC cable connector (302).

12. The power input connector assembly according to claim 11, characterized in that, The AC cable connector (302) includes a connector sub-assembly (308) comprising a housing (310), a connector position guarantee (CPA) device (312), a connector seal (314) configured to seal the housing (310) to a shield (222), and a connector seal retainer (322).

13. The power input connector assembly according to claim 12, characterized in that, The AC cable connector (302) includes a terminal position assurance (TPA) device (318) for receiving the plurality of AC electrical terminals (304), a cable seal (320), and a cable seal retainer (322) disposed within the connector subassembly (308).

14. A method (400) for assembling and disassembling a power inlet connector configured for use in charging an electric vehicle, the method (400) comprising: Provided (402) housing subassembly (102) including a pair of direct current (DC) terminals (106) configured to mate with corresponding DC terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle; Provided (404) a rear cover assembly (202) comprising a pair of electrical busbars (206) and a plurality of AC electrical terminals (208) having a first end (210) configured to mate with a corresponding AC electrical terminal of the power outlet connector of the electric vehicle charging device. The plurality of AC terminals (206) are inserted (406) into the terminal cavity defined by the housing subassembly (102); Connect (408) the housing subassembly (102) to the rear cover assembly (202); and By accessing (410) a threaded fastener via an access port (218) in the rear cover assembly (202), the threaded fastener is used to connect (412) the pair of electrical busbars (206) to the pair of DC electrical terminals (106). The access port (218) is positioned, sized, and arranged to allow access to the threaded fastener.

15. The method (400) according to claim 14, further comprising: An AC cable connector (302) having multiple AC cable terminals (304) is inserted (414) into a cover (222) defined by the cover assembly (202), wherein the multiple AC cable terminals (304) terminate multiple AC cables (306) in the electric vehicle; and The plurality of AC cable terminals (304) are coupled to the second end (224) of the plurality of AC terminals (208) (416).

16. The method (400) of claim 15, further comprising: The access port (218) in the cover assembly (202) connects (410) to the interface between the plurality of DC cables (216) and the plurality of electrical busbars (206) in the electric vehicle, the access port (218) being positioned, sized and arranged to allow access to the vehicle.

17. The method of claim 15, further comprising: Disconnect the plurality of busbars (206) from the plurality of DC terminals (106) (418); Disconnect the housing subassembly (102) from the cover assembly (202) (420); and Remove (422) the plurality of AC terminals (206) from the terminal cavity in the housing subassembly (102).

18. The method of claim 17, further comprising: Disconnect (424) the plurality of AC cable terminals (304) from the second end (224) of the plurality of AC terminals (208); and Remove the AC cable connector (302) from the cover (222) (426).

19. A power inlet connector assembly configured for use in charging an electric vehicle, the power inlet connector assembly comprising: A modular housing subassembly (102) includes a plurality of electrical terminals (106) configured to mate with corresponding electrical terminals of a power outlet connector of an electric vehicle charging device external to the electric vehicle. as well as A modular cover assembly (202) configured to connect and disconnect from the housing subassembly (102), and further configured to connect the plurality of electrical terminals to a DC cable (216) and an AC cable (306) in the electric vehicle, wherein the housing subassembly (102) and the cover assembly (202) are configured to be individually disconnected and replaced for servicing the power inlet connector assembly. The combined cover assembly (202) further includes a threaded fastener configured to connect and disconnect with a pair of electrical busbars (206) and a pair of DC terminals (106), wherein the threaded fastener is accessible via an access port (218) in the combined cover assembly (202) that allows tools to access the threaded fastener, and wherein the combined cover assembly (202) additionally includes a removable access plug (220) configured to enclose the access port (218).

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